Quality Engineer

SALMAN AFZAL

Industrial Engineer

**** **** ***, ** ***** **************@*****.*** (C) 313-***-**** www.linkedin.com/in/salman-afzal198

SUMMARY

-Utilizes research, analysis and problem-solving abilities to develop optimal solutions and improve processes-

Workflow Improvement: Assisted in redesigning assembly processes using Lean Principles and changed assembly line layouts to reduce waste, improve cycle times, units/labor hour by 33% (48 to 64) by reducing 16 operators.

Problem Identification & Rectification: Analyzed and solved body vibration & Vehicle Pull problems causing in the tire during tire development stage after conducting Root Cause Analysis.

Analysis and Testing: Performed statistical data analysis utilizing statistical software (Minitab and Excel) and witnessed various tests (Tire testing, Pressure testing, Dimensional inspection, Material testing) on proto tire.

Continuous Improvement

Production planning

Advanced product quality planning

Minitab, Excel QM, Solver

DMIAC, PDCA, 8D

Root Cause Analysis

Production Part Approval Process

HTML, CSS, PHP

SPC, FMEA, PFMEA

Value Stream Mapping

Supply chain management

Microsoft office

AutoCAD, Solid works

Regression Analysis

Equipment Troubleshooting

MRP/ERP, JIT, Forecasting

Lean Manufacturing

Process Improvement

Process Flow, Control and Pareto charts

Internal Auditing

EDUCATION

M.S., Industrial Engineer GPA 3.8 Wayne State University, Michigan May 2018 B.E., Mechanical Engineer GPA 3.7 SRM Easwari Engineering, India May 2016

Course: Automobile Engineering, Design of Machine Elements, Six Sigma, Quality Management systems, Engineering Risk and Decision Analysis, Production Systems, Lean Manufacturing, Flexible Manufacturing systems, Reliability Engineering.

CERTIFICATIONS

Lean Six Sigma Green Belt AutoCAD

CATIAv5 Solidworks

EXPERIENCE

Quality Engineer Intern, JK Tire & Industries Ltd, Chennai Mar 2015 – July 2016

Assisted Engineers in troubleshooting and Identifying problems in a mid-size Tire Manufacturing company.

Root Cause: Resolved two Quality issues - Body vibration & Vehicle pull problems causing in the tire.

Process improvement: Augmented production process by conducting root cause analysis and developed customized troubleshooting for engineering teams.

Software: Heavily used Minitab and MS Excel software to carry out various Analysis, Calculations and generate reports.

Quality Analysis: Identifying KPI's on basis of Cost, Quality and Delivery and find opportunities for Improvement.

Initiative:

Actively participate in the development and improvement plan of the plant using Lean principles.

Lead weekly 5S and kaizen meetings and played an active role in shop floor improvement.

Supporting development and implementation of inspection, testing and evaluation of products.

Relationship Building:

Assist in preparing Bill of materials and PPAP of new parts and existing parts as per customer specifications.

Work with suppliers to ensure testing requirements are being met and oversee PPAP process.

Developed key relationships with both internal and external customers.

PROJECTS

Regression Analysis test for Actual Temp. Vs Real Feel. Oct 2016 – Dec 2016

Led a team of 4 and Collected data of temperature to perform the regression analysis on the actual temperature.

Performed data analysis, using regression and scatter plots to find if any correlation, Skewness (Positive/negative).

Documented and drafted the results obtained using Minitab and Excel.

MRP DSS Project, Wayne State University, Michigan Feb 2018 – Apr 2018

Played a role of production planner of ‘Greek Manufacturing Company’ and developed decision support system for product scheduling using MRP, JIT, forecasted sales and achieved profit.

Conducted forecasting for the next 32 weeks, generated MRP sheet by using regression analysis and developed logic to increase the profit.

Utilizing Wasted Warehouse Storage Space Using AS/RS for GM plant Jan 2017 – Apr 2017

Proposed a model for an Automated Storage and increased the current storage area from 52% to 75%.

Performed various calculations, ROI, what-if and cost analysis to calculate returns after implementation of project.

Developed an improved layout model for the storage area using AutoCAD and Sketch up tool.

Application of 5s, Value Stream Mapping and Poka-Yoke to Tire Manufacturing Industry Aug 2017- Dec 2017

Developed Lean Manufacturing Environment in a tire industry. Spaghetti diagrams, the flow was analyzed, value stream maps, 5s reduced cycle times, Lead time and increase in the production rate.

Lead times reduced by 554.6 sec and achieved an improvement in process cycle efficiency from 20.28% to 35.78%.

Improvement of Customer Satisfaction at Aramark (Six Sigma Project) Aug 2017 – Dec 2017

Implemented DMAIC procedure to Increase the Speed of service and Improve the Temperature of the Food.

Performed Root cause and Capability analysis to find out the factors leading to defects.

Documented the SPG, Performed Pareto Analysis and reduced process sigma from 3.46 to 4.08.

ORGANISATIONS

IISE (Institute of Industrial systems and Engineers).

SAE (Society of Automotive Engineer)

Prepare the club’s budget, present it to the board for approval, and ensure that club activities adhere to the budget

Inform the club of its financial strengths and weaknesses.

Maintain accurate financial records throughout the year to be reviewed at any time by members, other officers, or administration.

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